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How to Build the Biggest Warp-free Door

Sing Core has long been in the business of building the biggest warp-free doors in the world. And now you can learn how to build the biggest warp-free door as well. The first thing to note is that Sing Core does not build doors, even though Sing Core is credited and called out in architectural specifications as Sing Core door(s).

Inventor Peter Sing’s patent and patent-pending inventions are deployed in Sing’s Sing Core factory to provide the warp-free basis for high-end millworks and the biggest door companies for building big doors, over 8 ft. tall and up to 50 ft. or more, that can be guaranteed not to warp, bend, twist, cup, or otherwise fail for 50 years.

New Door or Replacement Door

Sing Core assists in the building of either New Doors, doors that have not existed before, or Replacement Doors, doors that are being replaced and may have to be replicated to maintain the appearance of the original door, such as in the case of participating in a historical restoration.

How to Build the Biggest Warp-free Door

Since Sing Core does not build doors, it is up to the architect to imagine what size the new door should be and of what materials the door should be made of. In the case of replacement doors, Sing Core is provided all the specs based on the original door to be either replaced or replicated.

The following steps are followed in making a door with Sing Core inside:

Step 1: Answer questions, and estimate

  • What is the size (length, width, thickness) of the door?
  • How will you be finishing the door
  • What type of door hardware will be used (hinge, pivot, sliding, overhead, etc.)?
  • What style of door (flush, architectural, plank, French, Dutch, etc.)?
  • How and where will the door be used?
  • Will this be an interior or exterior door?
  • Are there other specifications (weight, insulation, sealing, etc.)?

Step 2: Re-evaluate and refer to Sing’s True Flat Team, if necessary

Evaluate your estimate and let Sing Core know if we can help meet your budget

The True Flat team is available to help you provide your customer with a door that fits within their budget.

Sing Core and the True Flat team can suggest ways of changing some of the details of the panel, such as, reducing the height/width or choosing a more cost-effective skin.

Steps might need to be made to modify Sing’s composite hybrid solid substrate to accommodate the challenges that may not have been noted in the original details gathered in Step 1.

Step 3: Manufacture specified Sing Core

The specific Sing Core substrate core is then manufactured in Sing’s factory by skilled workers who have been manufacturing Sing’s cores for years using Sing’s patented and patent-pending technologies. Occasionally, a new challenge is recognized that the true Flat Team has never seen before, that is when Sing get to inventing again, and when a solution is achieved, this will likely lead to another patented solution.

The core which is based on Sing’s insulated reinforced vertical grain torsion box core, may or may not be framed, and is sandwiched between two matching skins, ready to be used as door core.

If no other services are required, skip Step 4, and go directly to Step 5.

Step 4: Additional services

To further assist the millworks and door companies in the manufacturing process, Sing Core may provide other services. For instance, the millwork or door builder may elect to have Sing’s factory apply additional outer door skins to the completed Sing Core substrate, in a sense, creating a custom door blank.

Some of the additional services that Sing’s factory may provide, include:

  • Trimming
  • Adding exterior skins
    • Wood stave
    • Veneer
    • Cement board or concrete
    • High Pressure Laminate (HPL)
    • Fiberglass
    • Formica
    • Metal
      • Aluminum
      • Cold rolled steel
      • Copper
      • Galvanized steel
      • Hot rolled steel
      • Lead
      • Stainless steel
    • Impact/Bulletproof/Blast resistant materials
  • Light cutouts, openings, for glass inserts
  • Routing for architectural grooves

Step 5: Package and ship to millwork or door company

Sing’s factory packages and ships the door core or prepared blank to the millwork or door company who will finish the door.

Step 6: Finishing

Finishing takes place at the millwork or door company who installs hardware, finishes, and hangs the door, which is ready for installation.

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Panel Carry


What Are Sing Honeycomb Panels?

Sing Honeycomb is a sandwich panel composite material with built in structural grids. Our grids are made of vertical grain renewable veneer wood fiber, and foam. We construct our Singcore in a fashion similar to torsion box technology most commonly found in the airplane industry. This technology is what allows our panels remain strong, lightweight, and flat without denting, cracking, and warping. See a comparison here. Inventor Peter Sing uses this torsion box technology, along with wood fiber and foam to create patented Sing Honeycomb: the incredibly strong, true flat, lightweight, renewable composite material of the future. Check out our products section to see a few different applications.

Sing Core cut away to see torsion box core Singcore Core Structure
The secret of the Sing Honeycomb panel is in the Singcore. Our Singcore utilizes torsion box sandwich core technology to ensure strength, and allow our product to be lightweight.
16' x11' factory door made with 6mm Luan Plywood Skins True Flat
Sing Honeycomb sandwich panels utilize torsion box strength technology in order to ensure flatness.
Vertical Grain Veneer is the heart of our core Vertical Grain Wood Fiber
The heart of soul of Sing Honeycomb is in our patented Singcore invention. The core utilizes renewable vertical grain wood fiber and foam, to create our strong, lightweight, composite material.
Sing Core factory doors are very strong Strength
Sing  Honeycomb is stronger than solid wood, plastic, metal, glass, brick, and  concrete in terms of lbs. per lbs comparison.
Sing Core factory doors are very light weight Lightweight
Sing Honeycomb sandwich panels are strong, flat, and lightweight. A  4’ x  8’ x 1 ½” panel with 1/8 “ Luan skins, and solid wood edging weighs in at about 55 lbs. A standard sheet of plywood weighs in at about 96 lbs.

Sinc Core panels are resistant to rot Rot Resistant
Even without coating, Sing Honeycomb sandwich panels outlast plywood, solid wood, MDF, and particle board. Plywood and engineered wood rot crack because of the weak glue layers. Sing Honeycomb panels last because underneath the skins lie Singcore, which keeps the panels flat through torsion box technology, and therefore doesn’t allow the panel to crack.

 

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Trade Show How to Build Moveable Walls

Click Here for Trade Show Panels

What Are Sing Honeycomb Panels?

Sing Honeycomb is a sandwich panel composite material with built in structural grids. Our grids are made of vertical grain renewable veneer wood fiber, and foam. We construct our Singcore in a fashion similar to torsion box technology most commonly found in the airplane industry. This technology is what allows our panels remain strong, lightweight, and flat without denting, cracking, and warping. See a comparison here. Inventor Peter Sing uses this torsion box technology, along with wood fiber and foam to create patented Sing Honeycomb: the incredibly strong, true flat, lightweight, renewable composite material of the future. Check out our products section to see a few different applications.

Sing Core cut away to see torsion box core Singcore Core Structure
The secret of the Sing Honeycomb panel is in the Singcore. Our Singcore utilizes torsion box sandwich core technology to ensure strength, and allow our product to be lightweight.
16' x11' factory door made with 6mm Luan Plywood Skins True Flat
Sing Honeycomb sandwich panels utilize torsion box strength technology in order to ensure flatness.
Vertical Grain Veneer is the heart of our core Vertical Grain Wood Fiber
The heart of soul of Sing Honeycomb is in our patented Singcore invention. The core utilizes renewable vertical grain wood fiber and foam, to create our strong, lightweight, composite material.
Sing Core factory doors are very strong Strength
Sing Honeycomb is stronger than solid wood, plastic, metal, glass, brick, and concrete in terms of lbs. per lbs comparison.
Sing Core factory doors are very light weight Lightweight
Sing Honeycomb sandwich panels are strong, flat, and lightweight. A 4’ x 8’ x 1 ½” panel with 1/8 “ Luan skins, and solid wood edging weighs in at about 55 lbs. A standard sheet of plywood weighs in at about 96 lbs.
Sinc Core panels are resistant to rot Rot Resistant
Even without coating, Sing Honeycomb sandwich panels outlast plywood, solid wood, MDF, and particle board. Plywood and engineered wood rot crack because of the weak glue layers. Sing Honeycomb panels last because underneath the skins lie Singcore, which keeps the panels flat through torsion box technology, and therefore doesn’t allow the panel to crack.
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Going Green

Environment & Economy Friendly

How is Sing Core “Green”, and why is it the most earth-friendly way to use both natural and man-made materials?

LCA (Life Cycle Assessment) provides a “cradle to grave” measurement of a product’s environmental impacts from raw material extraction and manufacturing through distribution, use, maintenance, and disposal.  An obvious example is a coffee or tea cup made of Styrofoam compared to a coffee mug made of the same material but enclosed in a solid container.  Solo cups are only used once then disposed of after use, unnecessarily filling our landfills.  Imagine that the same Solo cup material put into a permanent coffee mug, could last ten years without being replaced.  Sing Core protects the foam inside durable wood frameworks.  LCA studies show that using wood is less harmful to the environment than steel or concrete in terms of embodied energy, global warming potential, air emissions, water emissions, and solid waste production. Sing Honeycomb core structure is made of 100% natural vertical grain wood veneer.  This sets us apart from our counterparts who use only paper, particle board, aluminum, and plastic. Here at Sing Core, environmentally friendly construction is our mission.

Green-eco-friendly-sing-coreLow Energy Production

Sing Core’s patented manufacturing process is the most efficient and economical way to make sandwich panels with a veneer torsion box core.  The materials used in Sing Core sandwich panels use low energy to produce.  The adhesive used in Sing Core panels is produced in a much more efficient way than the minerals for nails are mined. The veneer is made of scrap material from Washington mills and the foam core is 20% recycled.

Renewable

Sing Core’s structure is made of natural vertical grain wood veneer.  This sets us apart from our counterparts who make cores with particle board.  It requires energy to break wood down into pulp and reconstruct it into particle board.  Veneer uses the natural strength of the wood fiber.  Life Cycle Assessment studies show that using wood veneer is less harmful to the environment than steel or concrete in terms of embodied energy, global warming potential, air emissions, water emissions, and solid waste production.  Here at Sing Core, environmentally friendly construction is our mission.

Non-Toxic

The structural glue and finishing stains that we use are all non-toxic and formaldehyde free.

Recycled

Our foam core has a recycled content of 20% and is 100% recyclable.

Energy Saving

Insulated, draft-free sandwich panels save your heating costs Sing has a long term stable R-Value. Sing Core panels assemble and install quickly, saving you man power and time.

Long Lasting

Sing torsion box sandwich panels are warrantied for ten years*, but may last much longer. This means Sing Core products will not need replacement or disposal for many years, cutting down on the resources used to manufacture panels. The foam used in Sing Core panels comes with a 20-year thermal performance warranty, dimensional stability, compressive strength, and water resistant properties. See instructions for repair and recycling.

This is a Sing Core overhead garage door panel compared next to a typical steel overhead garage door panel. Same size and thickness but as you can see the steel panel buckles with only a few pounds put on it while the Sing Core panel holds almost all of Inventor Peter Sings weight without any problem.

*See Warranty

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Door Condition Plank

Applications -> Building Components -> Doors -> Plank Grade

Plank Method

 

Sing Honeycomb plank method doors are our most expensive doors. These doors look like solid wood, and can be any height and any width. These doors have thicker veneer than wood grain. These are formed by making separate planks, then connecting the planks separately.

Above: Individual planks ready to be connected

Above: Connect Sing Honeycomb planks before gluing

 

Above: Finished Sing Honeycomb plank door

Above: Sing Honeycomb white cedar oversized plank method Door

 

Pricing

Our plank method doors are the second most expensive doors. We custom create quotes for individual projects. Please contact us to get started.

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Door Condition Wood Grain

Applications -> Building Components -> Doors -> Wood Grain

Wood Grain Method

 

Wood Grain method Sing Honeycomb doors are our second most expensive finished doors. These oversized panels are joined together with a hidden Sing Honeycomb biscuit (see paint grade method to learn more about the Sing Honeycomb biscuit), and finished by covering our wood substrate with wood planks.

 

 

 

Left: Wood Grain Finished White Oak oversized Sing Honeycomb Door

 

 

 

 

 

 

 

 

 

 

 

 

 

Right: Side view of wood grain finished white oak oversized Sing Honeycomb door

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Left: Stained vertical grain Cedar wood grain finished Sing Honeycomb Door

 

 

 

 

 

 

 

 

 

 

Pricing

Our wood grain method doors are the second most expensive doors we offer. We custom create quotes for individual projects. Please contact us to get started.

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Paint-Grade Door Panels

Applications -> Building Components -> Doors -> Paint Grade

Paint Grade Method

Paint grade method Sing Honeycomb panels are our second least-expensive finished doors. These oversized panels are joined together with a hidden Sing Honeycomb biscuit.

Left: Sing Honeycomb oversized doors utilize Sing Honeycomb biscuit to connect pieces together

Connecting the Sing Honeycomb pieces together:

Left: Finished paint-grade oversized circle is ready to go

Paint-grade method doors need to be finished after being received by our customers. Typically this just means using putty on the joint, sanding, and painting.

 Above: Oversized paint-grade method door ready to be shipped

 

Pricing

Our paint-grade method doors are the second least-expensive doors we offer. We custom create quotes for individual projects.  Please contact us to get started.



door door finish paint grade door Sing paint grade large door

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Door Condition Pole Barn

Applications -> Building Components -> Doors -> Pole Barn Door

Sing Honeycomb doors that come pole barn method are oversized doors that are made of standard 8′ x 4′ panels, connected through trim or molding. This makes the seam(s) of the door visible.

Left: Sing Honeycomb Pole Barn method over-sized door is ready for trim!

 

 

 

Right: Sing Honeycomb over-sized pole barn doors with trim are ready to be painited!

 

 

 

 

 

 

Left: Industrial pole barn door styled sliding door

Pricing

Our pole barn method doors are the least expensive doors we offer. We charge standard 4′ x 8′ panel for the entry price point.

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Dunnage

Products > SING CORE Dunnage and Storage Solutions

 

Dunnage

torsion box, sandwich panel, honeycomb panel, lightweight panel

SingCore cutaway.

The advantages of using SingCore blocks as dunnage and Sing panels for veneer and plywood holding trays:

The super-wide and lightweight super-strong and high compression strength SingCore blocks evenly distribute the weight and allow easy access for forklifts. This minimizes the opportunity for damaging high quality, expensive veneer, plywood, and other sheet goods.

Sing panels come 4 ft x 8 ft x 2.75 inches thick and will work with Sing dunnage to enhance product quality and make your factory happier.

You may purchase Sing panels to cut into the desired width of strips to use as Sing dunnage.

 

To order Sing panel products, fill out the order form, here.